Fluid flow control devices and systems, and methods of flowing fluids therethrough

ABSTRACT

Fluid flow control devices comprise a body including a central aperture extending along a longitudinal axis therethrough and a plurality of channels extending from an outer sidewall of the body to an inner sidewall of the body. At least one first channel may intersect at least one other channel. Fluid flow control systems, methods of forming fluid flow control devices, and methods of flowing a fluid through a fluid flow control device are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. patent application Ser. No.12/473,007, filed May 27, 2009, now U.S. Pat. No. 8,881,768, issued onNov. 11, 2014, the disclosure of which is hereby incorporated herein inits entirety by this reference.

TECHNICAL FIELD

The present disclosure relates generally to fluid flow control devices.More particularly, embodiments of the present disclosure relate todevices configured reduce a pressure and energy of a fluid passingtherethrough.

BACKGROUND

In many areas of industry, it is often necessary to reduce the pressureand energy of fluids (both liquids and gases) within a pipeline. One ormore control devices may be employed for this purpose. Various designsfor control devices have been presented in the art. For example, adevice may be employed to divide the flow through the device into aplurality of separate streams configured as a plurality of tortuousfluid flow paths within the device. As fluid passes through the tortuousfluid flow paths, the fluid is caused to change direction many times.Furthermore, as the fluid travels through the tortuous fluid flow paths,the overall cross-sectional area of the fluid flow path may increase toprovide a decrease in the velocity of the fluid within the flow path.The fluid pressure and energy of the fluid is partially dissipated alongsuch paths as a result of losses caused by friction between walls of thepath, rapid changes in fluid direction and expansion or contractionchambers. These devices may include what are commonly referred to as“tortuous path trim devices.”

Fluid flow control devices may conventionally take the form of a stackof disks or a plurality of concentric cylindrical sleeves. In the formerdesign, a plurality of substantially planar disks is stacked on top ofone another to provide a hollow, cylindrical structure. Such structuresare commonly referred to as “valve trim disk assemblies.” Each diskgenerally includes a plurality of voids formed through the disk. Thedisks are aligned and stacked together such that a plurality ofcontinuous, tortuous fluid paths are provided by the voids in the disksthat extend from the central region of the hollow, cylindrical valvetrim disk assembly to the exterior of the valve trim disk assembly. Inthe latter design, the sleeves are radially perforated with theperforations of adjacent sleeves being offset to cause the fluid to flowin a tortuous path. The sleeves are separated by intermediate annularpassages which allow the fluid passing therethrough to expand before itthen has to contract to pass through the perforations of the nextsleeve. The specific geometric arrangement of such designs is configuredto allow the pressure of the fluid of each stream to drop in relativelysmall increments and in many stages.

A fluid flow control device is often provided within a body of a valve,such as a control valve, having a body that is conventionally configuredto direct the fluid from an inlet towards the hollow, cylindrical fluidflow control device. The valve also may be configured to direct fluidpassing through the fluid flow control device to the exterior thereoftowards a fluid outlet. The valve includes a piston, ball, disk or otherdevice configured to be inserted into a central region of the valve tointerrupt fluid flow through and close the valve.

Pressurized fluids contain stored mechanical potential energy. The fluidflow control device dissipates this energy by reducing the pressure andvelocity of the fluid. As the fluid flows through the fluid pathways,the fluid flow may be turbulent. Turbulent fluid has associated pressureand velocity fluctuations that act upon the structural elements of thepipes and fluid control devices in which the fluid is flowing. Thesepressure and velocity fluctuations are generally accompanied by otherproblems such as erosion, noise, vibration and cavitation. In manyapplications, these accompanying problems are undesirable orunacceptable characteristics of a fluid flow control device.

BRIEF SUMMARY

Various embodiments of the present disclosure comprise fluid flowcontrol devices. In one or more embodiments, a fluid flow control devicemay comprise a body that includes a central aperture therethroughextending along a longitudinal axis thereof. At least one first channelmay extend from an outer sidewall of the body to an inner sidewall ofthe body. At least one second channel may extend from the outer sidewallof the body to the inner sidewall of the body and intersect the at leastone first channel.

In one or more additional embodiments, a fluid flow control device maycomprise a body that includes a plurality of disks coupled axiallytogether along a longitudinal axis. At least one disk of the pluralityof disks may comprise a plurality of grooves in a surface thereofextending from an outer diameter to an inner diameter of the at leastone disk and configured so that at least two of the plurality of groovesintersect.

Additional embodiments of the present disclosure comprise fluid flowcontrol systems. One or more embodiments of such systems may comprise afluid inlet and a fluid flow control device positioned in relation tothe fluid inlet so that a fluid passing from the fluid inlet flowsthrough the fluid flow control device. The fluid flow control device maycomprise at least one first channel extending from an outer sidewall ofa body to an inner sidewall of a central aperture extending through thebody. At least one second channel may extend from the outer sidewall ofthe body to the inner sidewall of the body and intersect the at leastone first channel.

Other embodiments comprise methods for forming a fluid flow controldevice. One or more embodiments of such methods may comprise forming atleast a first groove in a surface of at least one disk. The at least afirst groove may extend from an outer diameter of the at least one diskto an inner diameter thereof. At least another groove may be formed inthe surface of the at least one disk extending from the outer diameterto the inner diameter of the at least one disk and intersecting the atleast a first groove. The at least one disk may be coupled to at leastanother disk.

In yet further embodiments, the disclosure comprises methods for flowinga fluid through a fluid flow control device. In one or more embodimentsof such methods, a fluid may be flowed through a channel that extendsbetween an outer surface of a body and an inner surface of an apertureextending through the body. Fluid may also be flowed through at leastone second channel that extends between the outer surface and the innersurface of the body and that intersects at least a portion of thechannel The fluid flowing through the channel may be impinged into thefluid flowing through the at least one second channel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a cross-sectional view of a fluid flow control systemcomprising a valve assembly that includes a fluid flow control deviceaccording to at least one embodiment.

FIG. 2 illustrates an isometric view of the fluid flow control device ofFIG. 1 according to one or more embodiments.

FIG. 3 is a perspective view of a cut-away section of the fluid flowcontrol device comprised of two or more disks. FIG. 3A is a perspectiveview of a cut-away section of the fluid control device comprised of twoor more disks having linear channels. FIG. 3B is a perspective view of adisk having a channel that varies by width and depth.

FIG. 4 is a plan view of a disk comprising a plurality of arcuatechannels according to at least one embodiment and illustrating a fluidflow through some of the channels. FIG. 4A is a perspective view of acut-away section of the fluid control device comprised of three or fewerdisks having channels with a greater depth than the channels shown inFIG. 3. FIG. 4B is a perspective view of a disk having a channel with agreater width than the channels shown in FIG. 3.

FIG. 5 is an elevational view of a fluid flow control device employed ina fluid flow control system according to one embodiment.

DETAILED DESCRIPTION

The illustrations presented herein are, in some instances, not actualviews of any particular fluid flow control device, seat retainer, orcontrol valve, but are merely idealized representations which areemployed to describe the present disclosure. Additionally, elementscommon between figures may retain the same numerical designation.

Various embodiments of the present disclosure comprise fluid flowcontrol devices. FIG. 1 illustrates a cross-sectional view of a fluidflow control system comprising a valve assembly 100 that includes afluid flow control device 110 according to at least one embodiment. Thevalve assembly 100, which may also be characterized as a control valve,comprises a valve body 120 defining a fluid inlet 130 and a fluid outlet140, which in use may be connected to pipes (not shown) that transportfluid to and from the valve assembly 100. Although the valve assembly100 is shown with an inlet 130 and an outlet 140, the valve assembly 100may be employed in uses in which the fluid flow is reversed. Thedirection of fluid flow may be selected according to the particularapplication.

A plug chamber 150 may be positioned between the fluid inlet 130 and thefluid outlet 140 and a plug head 160 may be disposed therein. The plughead 160 is coupled to a shaft 165 and is configured to move within theplug chamber 150 between a fully open position and a closed position. Inthe open position, the plug head 160 is retracted to provide fluidcommunication between the fluid inlet 130 and the fluid outlet 140,allowing fluid to flow from the fluid inlet 130 to the plug chamber 150and into the fluid outlet 140. In the closed position, the plug head 160is in abutment with a valve seat 170, forming a seal that physicallyinterrupts fluid communication between the fluid inlet 130 and the fluidoutlet 140, and effectively blocks fluid flow through the valve body120.

The shaft 165 may include an actuator controllably coupled thereto andconfigured to control the position of the plug head 160. The actuatormay comprise any suitable actuator known to those of ordinary skill inthe art. In addition, a positioner may be operably coupled to theactuator. The positioner may comprise any conventional positionersuitable for use with the selected actuator as is known to those ofordinary skill in the art.

As illustrated in the embodiments depicted in FIG. 1, the fluid flowcontrol device 110 may be configured as a seat retainer disposed on thevalve seat 170 and in the plug chamber 150. The fluid flow controldevice 110 is positioned and configured so that all the fluid passingthrough the valve body 120 flows through the fluid flow control device110.

FIG. 2 illustrates an isometric view of the fluid flow control device110 of FIG. 1 according to one or more embodiments. The fluid flowcontrol device 110 comprises a body 210 having a central aperture 220extending therethrough along a longitudinal axis 230 of the body 210.The body 210 includes a plurality of channels 240 extending between andin communication with an outer surface 250 and an inner surface 260 ofthe body 210. At least one channel 240 is configured to intersect atleast another channel 240.

In at least one embodiment, the body 210 of the fluid flow controldevice 110 may comprise a plurality of substantially planar disksstacked adjacent to one another. FIG. 3 is a perspective view of acut-away section of the fluid flow control device 110 (FIGS. 1 and 2)comprised of two or more disks 310. At least one disk 310 comprises twoor more channels 240 extending radially from the outer diametric extentto the inner diametric extent of the disk 310. At least one channel 240is configured to intersect at least one other channel 240.

In other embodiments, the two or more channels 240 may comprise groovesformed in a surface of a disk 310 and comprising sidewalls extending atleast substantially perpendicular to the surface. The channels 240 mayextend nonlinearly over the surface of the disk 310 in at least someembodiments. For example, in at least some embodiments the channels 240may extend substantially arcuately over the surface of the disk 310. Inother embodiments, the channels 240 may extend substantially linearlyover the surface of the disk 310, as shown in FIG. 3A. The channels 240may be configured with a selected angle of intersection between twochannels 240 to customize the effects of the intersections.

In some embodiments, the channels 240 may comprise a substantiallyconstant width and depth, while in other embodiments the channels 240may comprise a varying width, depth or a combination thereof. Forexample, FIG. 3B shows a disk 310 having a channel 240 that varies inboth width and depth. The width and/or depth of the channels 240 may bevaried to customize the location of pressure drops through the channels240 and may be configured based on the particular application.Furthermore, the depth of the channels 240 may be selected according tothe particular application and configuration of the particular fluidflow control device.

Referring to FIG. 3, each of the two or more channels 240 may beconfigured to intersect at least one other channel 240, theintersections comprising energy reduction stages 320. The number ofstages 320 can be determined by the number of intersections and may beselected based on the particular application. For example, in someembodiments, each channel 240 may comprise a single stage 320. In otherembodiments, each channel 240 may comprise a plurality of stages 320. Byway of example and not limitation, each channel 240 may comprise betweenone and seven stages 320. The number of stages 320 may exceed seven inother embodiments.

The channels 240 may be configured to intersect the outer surface 250,the inner surface 260, as well as another channel 240 at a particularangle. The angle of intersection may be selected to maximize the effectson the fluid passing through the fluid flow control device 110 and maydiffer according to the particular application. Furthermore, at leastsome of the angles of intersection between various stages 320, the outersurface 250, and the inner surface 260 may differ for a single channel240. For example, in embodiments comprising arcuate channels 240, theangle of intersection at the outer surface 250, at a first stage 320, atone or more additional stages 320, and at the inner surface 260 may eachcomprise a different value.

The fluid flow control device 110 may comprise any of a variety ofmaterials depending on the particular application. By way of example andnot limitation, embodiments of fluid flow control devices 110 of thepresent disclosure may comprise a metal or metal alloy, such as steel, aceramic, or other suitable material. In embodiments comprising aplurality of disks 310, channels 240 may be formed and the disks 310 maybe disposed adjacent each other and secured in position, as will bedescribed in more detail below.

FIG. 4 is a plan view of a disk 310 comprising a plurality of arcuatechannels 240 according to at least one embodiment and illustrating afluid flow through some of the channels 240. A fluid may be flowedbetween the outer surface 250 and the inner surface 260 of the fluidflow control device 110 (FIG. 1). In FIG. 4, the fluid flow is shown asflowing from the outer surface 250 to the inner surface 260, known as a“flow over” design. However, in other embodiments, the fluid flow may beconfigured to flow from the inner surface 260 to the outer surface 250,known as a “flow under” design, depending on the particular application.

Fluid flows through the plurality of channels 240, which extend betweenthe outer surface 250 and the inner surface 260. Each channel 240intersects one or more other channels at stages 320. For example, in theembodiment depicted by FIG. 4, each channel comprises four stages. Asthe fluid flows through each channel 240, the fluid in each channel 240impinges the fluid from one or more other channels 240 at the stages320. At the points of impingement (i.e., at each stage 320) the fluid inthe two intersecting channels 240 is forced to fit simultaneouslythrough an area comprising a width of a single channel 240. In otherwords, twice the fluid volume is forced to flow through the width of asingle channel 240, resulting in a sudden contraction of the areathrough which the fluid may flow. As the fluid continues into one of thetwo intersection channels 240, the fluid experiences a sudden expansionof the area through which the fluid may flow, as compared to the arearelating to the intersection. The sudden contraction and expansion ofthe area through which the fluid flows results in reducing the pressureof the fluid flowing therethrough. The fluid may subsequently exit thechannel 240 at a lower pressure than the pressure at which the fluidentered the channel 240.

Additional embodiments of the present disclosure comprise methods offorming fluid flow control devices. Embodiments of such methods aredescribed with reference to FIGS. 1-5. As set forth hereinabove, atleast some embodiments of a fluid flow control device 110 of the presentdisclosure may comprise a plurality of substantially planar disks 310stacked adjacent to one another. The disks 310 may be formed with asubstantially round shape and including a central aperture 220 formedtherein. The thickness of the disks 310 may be selected in accordancewith the particular application. By way of example only, at least someembodiments may employ disks 310 comprising a thickness selected ofabout 0.125 inch and 0.5 inch (approximately 3.175 mm and 12.7 mm). Inother embodiments, the disks 310 may comprise a thickness greater than0.5 inch (12.7 mm).

Fluid passageways in the form of channels 240 may be formed into thedisk 310. In at least some embodiments, the channels 240 may be formedusing a cutter to cut the channels 240 into the disk 310. By way ofexample and not limitation, the cutter may comprise a hole saw, whichmay be suitable for forming arcuate channels 240, or a rotary saw, whichmay be suitable for forming substantially linear channels 240. Thecutter may plunge partway into the disk 310 to a selected depth withoutcutting completely through the disk 310. A single cut with a cutter,such as a hole saw, may form two channels 240 at the same time. Forexample, a single cut with a hole saw may form the channels 440A and440B in FIG. 4. At least two channels 240 may be formed in the surfaceof the disk 310 that intersect at some point to form a stage 320.

The depth of the channels 240 may vary depending on the particularapplication and the thickness of the disks 310. For example, a thinnerdisk 310 will only allow for more shallow channels 240, while arelatively thick disk 310 will allow for much deeper channels 240. In atleast one embodiment, only one to three substantially thick disks 310may be employed and thick channels 240 may be formed therein. Such athick disk 310 with deep channels 240 may be suitable for variousapplications, such as a valve having only “on” or “off” capabilities.

The width of the channels 240 may also vary according to the particularapplication, as shown in FIG. 4B. Typically, the width of the channels240 may be determined by the thickness of the cutter used to form thechannels 240. However, a channel 240 that is wider than the thickness ofthe cutter may be formed by plunging the cutter two or more times intothe surface of the disk 310 at nearly the same location.

The disks 310 may be disposed adjacent to each other and secured inplace. The disks 310 may be disposed so that the surface of one disk 310with the channels 240 therein is positioned adjacent to the surface ofanother disk 310 having no channels 240 therein. In other embodiments,the disks 310 may be disposed so that the surface of one disk 310 havingchannels 240 therein is positioned adjacent to the surface of anotherdisk 310 also having channels 240 therein. In various configurations ofsuch embodiments, the channels 240 in each surface may be orientedsubstantially aligned or partially offset, such as the fluid passagewaystaught in U.S. Patent Publication No. 2006/0191584, the entiredisclosure of which is incorporated in its entirety herein.

In some embodiments, the disks 310 may include through holes (not shown)formed between the channels 240 and bolts or pins (not shown) may beemployed through the through holes for aligning and securing the disks310 together. In other embodiments, the stack of disks 310 may besecured by an adhesive or by brazing or welding the disks 310 together.In embodiments in which the disks 310 comprise ceramic materials, thedisks 310 may be secured to one another using techniques known to thoseof ordinary skill in the art for securing ceramic materials together.

Although the disclosure has described embodiments of a fluid flowcontrol device 110 employed in a valve, the invention is not so limited.Various embodiments of fluid flow control devices of the presentdisclosure may be employed in various applications for reducing thepressure and/or energy of a fluid flowing through a system. FIG. 5 is anelevational view of a fluid flow control device 510 employed in a fluidflow control system according to one embodiment. The fluid flow controldevice 510 may be coupled to a fluid inlet, such as pipe 520, at onelongitudinal end and may be closed at the opposing longitudinal end.Fluid flowing through the pipe 520 may enter a central aperture of thefluid flow control device 510 and may pass through a plurality ofchannels 240 (FIGS. 2-4) to the exterior. Such a fluid flow controldevice 510 may be employed in various applications, such as, but notlimited to, flowing a fluid into a fluid tank, flowing a fluid into ariver or other fluid stream, an exhaust system for releasing a fluidinto the surrounding environment, or flowing fluid from the pipe 520into another pipe.

While certain embodiments have been described and shown in theaccompanying drawings, such embodiments are merely illustrative and notrestrictive of the scope of the disclosure, and this disclosure is notlimited to the specific constructions and arrangements shown anddescribed, since various other additions and modifications to, anddeletions from, the described embodiments will be apparent to one ofordinary skill in the art. Thus, the scope of the disclosure is onlylimited by the literal language, and legal equivalents, of the claimswhich follow.

What is claimed is:
 1. A method of forming a fluid flow control device,comprising: forming at least one first groove in a surface of at leastone disk extending from an outer diameter of the at least one disk to aninner diameter thereof; forming at least one second groove in thesurface of the at least one disk extending from the outer diameter ofthe at least one disk to the inner diameter thereof and intersecting theat least one first groove, wherein at least two intersecting grooves fitsimultaneously through an area having an approximate width of a singlegroove, segments of each of the at least one first groove and the atleast one second groove being bounded by substantially continuous,parallel groove sidewalls extending along a length of each of thesegments; and coupling the at least one disk to at least another disk.2. The method of claim 1, wherein forming the at least one first grooveand the at least one second groove in the surface of the at least onedisk comprises plunging a cutter partway into the surface of the atleast one disk without cutting completely through the at least one disk.3. The method of claim 1, wherein forming the at least one first grooveand the at least one second groove in the surface of the at least onedisk comprises forming at least one first nonlinear groove and at leastone second nonlinear groove in the surface of the at least one disk. 4.The method of claim 3, wherein forming the at least one first nonlineargroove and the at least one second nonlinear groove in the surface ofthe at least one disk comprises plunging a hole saw into the surface ofthe at least one disk.
 5. The method of claim 1, wherein forming the atleast one first groove and the at least one second groove in the surfaceof the at least one disk comprises forming at least one first lineargroove and at least one second linear groove in the surface of the atleast one disk.
 6. The method of claim 1, further comprising forming theat least one first groove and the at least one second groove in thesurface of the at least one disk to vary at least one of a width and adepth of the at least one first groove and of the at least one secondgroove between the outer diameter and the inner diameter of the at leastone disk.
 7. The method of claim 1, wherein coupling the at least onedisk to at least another disk comprises at least one of bolting,adhering, brazing, and welding the at least one disk to the at leastanother disk.
 8. The method of claim 4, wherein plunging a hole saw intothe surface of the at least one disk comprises simultaneously formingtwo grooves in the surface of the at least one disk with a single cut ofthe hole saw.
 9. The method of claim 3, wherein forming at least onefirst nonlinear groove and at least one second nonlinear groove in thesurface of the at least one disk comprises forming at least one firstsubstantially arcuate groove and at least one second substantiallyarcuate groove in the surface of the at least one disk.
 10. The methodof claim 1, wherein forming the at least one first groove and the atleast one second groove in the surface of the at least one diskcomprises forming the at least one first groove and the at least onesecond groove in the surface of at least one disk having a thickness ofbetween about 0.125 inch and about 0.5 inch.
 11. The method of claim 1,wherein the at least one first groove intersects with between one andseven other grooves.
 12. The method of claim 1, further comprisingpositioning the coupled at least one disk and at least another diskbetween a fluid inlet and a fluid outlet of a valve assembly.
 13. Themethod of claim 12, further comprising retaining a valve seat with thecoupled at least one disk and at least another disk.
 14. A method offlowing a fluid through a fluid flow control device, comprising: flowinga fluid through a first substantially arcuate channel that extends froman outer surface of a body to an inner surface of an aperture extendingthrough the body; flowing a fluid through at least one secondsubstantially arcuate channel that from the outer surface of the body tothe inner surface of the aperture, the at least one second substantiallyarcuate channel intersecting the first substantially arcuate channel,the first substantially arcuate channel and the at least one secondsubstantially arcuate channel being bounded by channel sidewallsextending smoothly and continuously from the outer surface of the bodyto the inner surface of the aperture; and impinging the fluid flowingthrough the first substantially arcuate channel into the fluid flowingthrough the at least one second substantially arcuate channel, whereinthe intersecting channels fit simultaneously through an area having anapproximate width of a single channel.
 15. The method of claim 14,wherein flowing the fluid through the first substantially arcuatechannel and through the at least one second substantially arcuatechannel comprises flowing the fluid through channels being bounded byparallel channel sidewalls.
 16. The method of claim 14, wherein flowingthe fluid through the first substantially arcuate channel and throughthe at least one second substantially arcuate channel comprises flowingthe fluid through the first substantially arcuate channel and throughthe at least one second substantially arcuate channel from the outersurface of the body to the inner surface of the aperture.
 17. The methodof claim 14, wherein flowing the fluid through the first substantiallyarcuate channel and through the at least one second substantiallyarcuate channel comprises flowing the fluid through the firstsubstantially arcuate channel and through the at least one secondsubstantially arcuate channel from the inner surface of the aperture tothe outer surface of the body.
 18. The method of claim 14, whereinflowing the fluid through each of the first substantially arcuatechannel and the at least one second substantially arcuate channelcomprises flowing the fluid through at least four intersections withother channels.
 19. The method of claim 14, wherein flowing the fluidthrough the first substantially arcuate channel and through the at leastone second substantially arcuate channel comprises reducing the pressureof the fluid.
 20. A fluid flow control device, comprising: a bodycomprising a central aperture therethrough extending along alongitudinal axis thereof; at least one first channel extendingsubstantially arcuately from an outer sidewall of the body to an innersidewall of the body; and at least one second channel extendingsubstantially arcuately from the outer sidewall of the body to the innersidewall of the body and intersecting the at least one first channel,wherein two intersecting channels fit simultaneously through an areahaving an approximate width of a single channel.
 21. The fluid flowcontrol device of claim 20, wherein the at least one first channel andthe at least one second channel vary in at least one of width and depthbetween the outer sidewall and the inner sidewall of the body
 22. Thefluid flow control device of claim 20, wherein the at least one firstchannel and the at least one second channel each have a substantiallyconstant width and depth between the outer sidewall and the innersidewall of the body.